论文部分内容阅读
针对大型铝合金曲面零件电磁渐进成形工艺中板料不均匀变形的问题,基于ANSYS多物理场模块建立电磁场-结构场耦合模型,对成形过程进行数值模拟分析,研究电磁成形线圈结构参数对板料变形行为的影响,包括:线圈层数、线圈匝间距、线圈层间距、导线截面积和导线截面形状。研究表明,线圈层数增加,板料变形均匀性降低,而板料的变形量增大,多层线圈有利于提高线圈的强度和使用寿命;线圈匝间距与导线的宽度越接近,板料均匀变形效果越好;矩形导线截面的线圈相对圆形导线截面的线圈使板料变形更加均匀;线圈层间距和导线截面积对板料均匀变形影响不大,但是合理的结构参数可以提高线圈强度。提出了一种非等间距线圈结构,非等间距线圈产生的电磁场和电磁力是不均匀的,在板料半径1/3处受到的成形驱动力较大,而这种不均匀的变形力,进一步改善了电磁成形中板料的变形不均匀性,电磁成形平板线圈能与变形后的板料较好的贴合,使大型铝合金曲面零件电磁渐进成形能通过多次放电连续均匀塑性变形。通过实验验证了线圈结构优化设计的可靠性,实验结果与模拟结果基本一致,误差在12%以内。
Aiming at the problem of uneven deformation of sheet metal in electromagnetic progressive forming process of large aluminum alloy curved parts, an electromagnetic field-structure field coupling model was established based on ANSYS multiphysics module. The forming process was numerically simulated and analyzed. Deformation behavior of the impact, including: the number of layers, coil turn spacing, coil spacing, wire cross-sectional area and wire cross-sectional shape. The results show that the number of coil layers increases, the plate deformation uniformity decreases, and the sheet deformation increases, multi-layer coil is conducive to improving the coil strength and service life; coil turns and wire width closer to the plate uniform The deformation effect is better; the coil of the rectangular wire cross-section relative to the circular wire cross section makes the sheet deformation more uniform; the spacing of the coil layer and the cross-sectional area of the wire have little effect on the even deformation of the sheet, but reasonable structural parameters can improve the coil strength. A non-equidistant coil structure is proposed. The electromagnetic field and electromagnetic force generated by the non-equidistant coil are not uniform. The forming driving force is large at the 1/3 of the sheet radius, and the non-uniform deformation force, Further improve the sheet metal deformation in electromagnetic forming inhomogeneity, electromagnetically formed flat coil can be better with the deformation of the sheet fit, so that large-scale aluminum alloy curved parts of the electromagnetic progressive forming through repeated discharge continuous and uniform plastic deformation. The reliability of the optimal design of the coil structure is verified through experiments. The experimental results are in good agreement with the simulation results and the error is within 12%.